Method of placing a material transversely on a moving web

ABSTRACT

Disclosed herein is a method by which a material may be placed onto a moving web in a transverse orientation. At least two assemblies, which carry either a first and a second web or a single web, periodically overlap each other in an alternating fashion such that a material may be placed upon their respective carried webs in a transverse manner. The first and second assemblies translate in a direction of web movement in order to modify the velocity of the web carried upon the assembly. Thus, with the velocities of the assemblies capable of being varied, the material may be placed in a transverse manner upon the moving web along with various other orientations.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.10/779,338, filed Feb. 13, 2004, the substance of which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to a process by which a material can beplaced onto a moving web and more particularly to a process by which amaterial can be placed onto a moving web across at least a portion ofthe transverse width of the web.

BACKGROUND OF THE INVENTION

There are many processes which allow for the application of materialacross the transverse width of a web. However, many of these processesaccomplish this feat at the cost of affecting the speed of the entireweb.

An example of modifying the speed of only a portion of the web asopposed to modifying the speed of the entire web is shown in U.S. Pat.No. 5,693,165 issued to Schmitz. The Schmitz reference teaches that apair of translatable transport rollers may be used in conjunction with apair of stationary guide rollers to affect a velocity change in aportion of the web. The transport rollers are mounted on a sled which isperiodically translated along a frame. Because the web is looped aroundthe translatable transport rollers, as the sled translates along theframe in the direction of web feed, the web portion between the twotranslatable transport rollers has a velocity which is less than that ofthe overall web velocity. Therefore, a process could be implementedwherein a material is placed onto the portion of the web having areduced velocity.

European Patent Application EP-A-0 364 087 discloses an applicatordevice for applying layers of material generally transversely across anelongated web. The elongated web moves continuously through the devicein a web feed direction at a predetermined web speed. The devicecomprises two transport members which each turn the web 90 degrees inthe plane of the web. The web portion between the two transport membersis of constant length and extends perpendicular to the upstream portionof the web. The transport members are mounted on a sled which translatesin the web feed direction and the reverse web feed direction. When thesled translates in the web feed direction at a speed which equals theweb speed, the web portion between the transport members is stationaryrelative to the frame. A rotating applicator wheel having a tangentialspeed, which equals the linear speed of the air bars, can contact theweb portion to attach a layer of material. When the frame is translatedin the reverse web feed direction, the web portion is accelerated pastthe transport members to the web's downstream side.

From European Patent application EP-A-0 284 652 it is known to supplytensioned elastic ribbons transversely to a continuously moving web at ahigh speed. A number of applicator heads are mounted on a rotatablevertical shaft with each applicator head being connected to a radialarm. Upon rotation of the shaft, the arms pass over the moving web. Atthe position when a radial arm extends perpendicular to the web and hasa tangential velocity equal to the linear web speed, a pre-stretchedelastic is fed from the applicator head. A rotating anvil, which has acircumferential velocity equal to the linear web speed to minimize theshearing forces, contacts the applicator head upon attachment of theelastic.

Because the above apparatus has multiple arms, it can attach transverseparts to the moving web at a high speed and exert a low tension on theweb with the web speed remaining constant. But, the application ofcomplex parts in a transverse orientation to the web may requiremomentarily stopping the web at the position of the applicator device.In this instance, the above apparatus is less suitable.

It is an object of the present invention to provide a method by which amaterial may be applied to a moving web transversely without affectingthe overall processing speed of the web regardless of the complexity ofthe material to be applied to the web.

SUMMARY OF THE INVENTION

The present invention pertains to a method of placing a material on aplurality of webs. The method comprises the steps of providing a firstpath comprising a first upstream zone, a first downstream zone, and afirst intermediate zone which is disposed between the first upstreamzone and the first downstream zone. Also, a second path is providedcomprising a second upstream zone, a second downstream zone, and asecond intermediate zone which is disposed between the second upstreamzone and the second downstream zone. In addition, the first intermediatezone comprises a first assembly, and the second intermediate zonecomprises a second assembly.

A first web having a transverse width and a longitudinal centerline isprovided in the first upstream zone of the first path such that thefirst web is moving at a first web velocity in the positive x direction.The first assembly is provided for diverting the first web from thefirst upstream zone to the first intermediate zone of the first path.The first assembly also diverts the first web from the firstintermediate zone to the first downstream zone of the first path.

Similarly, a second web having a transverse width and a longitudinalcenterline is provided in the second upstream zone of the second pathsuch that the second web is moving at a second web velocity in thepositive x direction. The second assembly is provided for diverting thesecond web from the second upstream zone to the second intermediate zoneof the second path and for diverting the second web from the secondintermediate zone to the second downstream zone of the second path.

The method further comprises the step of periodically overlapping thefirst and second assemblies in an alternating fashion. This isaccomplished by translating the first assembly and the second assemblyin a positive x direction in a first plane and a negative x direction ina second plane. So, when the first assembly translates in the positive xdirection, the first web in the first intermediate zone has a velocity,with respect to the first assembly, which is less than the first webvelocity. Similarly, when the second assembly translates in the positivex direction, the second web in the second intermediate zone has avelocity, with respect to the second assembly, which is less than thesecond web velocity.

As the first and second assemblies are being overlapped, a material isbeing alternately applied across at least a portion of the transversewidth of the first web in the first intermediate zone and across atleast a portion of the transverse width of the second web in the secondintermediate zone. As a result of the alternate application of thematerial to the first web and the second web, the application of thematerial is continuous.

Alternatively, the claimed invention may be performed on a single webrather than the previously stated plurality of webs. In this instance,the method includes the step of providing a single web to a firstupstream zone such that the single web is moving at a first upstreamzone velocity. Also, a first assembly is provided for diverting thesingle web from a first upstream zone to a first intermediate zone. Thefirst assembly also diverts the single web in the first intermediatezone to a first downstream zone. From the first downstream zone, thesingle web is transported into a second upstream zone such that thesingle web is moving at a second upstream zone velocity in the positivex direction. In addition, a second assembly is provided for divertingthe single web from the second upstream zone to a second intermediatezone. The second assembly also diverts the single web from the secondintermediate zone to a second downstream zone.

This method further comprises the step of periodically overlapping thefirst and second assemblies in an alternating fashion. This isaccomplished by translating the first assembly and the second assemblyin a positive x direction in a first plane and a negative x direction ina second plane. So, when the first assembly translates in the positive xdirection, the single web in the first intermediate zone has a velocity,with respect to the first assembly, which is less than the firstupstream zone velocity. Similarly, when the second assembly translatesin the positive x direction, the single web in the second intermediatezone has a velocity, with respect to the second assembly, which is lessthan the second upstream zone velocity. As the assemblies periodicallyoverlap in an alternating fashion, a material is continuously appliedacross at least a portion of the transverse width of the single web inthe first intermediate zone and the transverse width of the single webin the second intermediate zone.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an apparatus that can carry out the presentinvention.

FIGS. 2-5 show a cross sectional view of the apparatus shown in FIG. 1illustrating an example of the motion of the two assemblies relative toone another.

FIGS. 6-7 show a cross sectional view of the apparatus shown in FIG. 1illustrating an example of the assembly motion that can perform anoptional step in the claimed invention.

FIG. 8 is a view of a portion of web material showing the uniformapplication of material onto the portion of the web.

FIG. 8A is a graph of an example of the velocity profiles of the firstand second assembly.

FIG. 9 is a view of a portion of web material showing a variant ofuniform application of the material onto the portion of the web.

FIG. 10 is a view of a portion of web material showing the angledapplication of the material onto the portion of the web.

FIG. 11 is a view of a portion of web material showing the angledapplication of the material onto the portion of the web.

FIG. 12 is a cross sectional view of an apparatus implementing anoptional step in the claimed invention.

FIG. 13 is a plan view of an apparatus that implements an optional stepin the claimed invention.

FIG. 14 is a plan view of an apparatus that can carry out a variation ofthe claimed invention.

FIG. 15 is an elevation view of an apparatus that can carry out avariation of the claimed invention.

DETAILED DESCRIPTION OF THE INVENTION

Definitions:

As used herein, the following terms have the following meanings:

The term “continuous” when used to refer to a process, means that theprocess, when in operation, can run without stopping; however, theprocess can be stopped. When used to refer to a web, the term“continuous” means that the web subjected to the process is sufficientlylong such that the first and second assemblies, later defined herein,can each perform at least two complete cycles.

The term “web,” as used herein, implies a continuous web and maycomprise non-wovens, wovens, films, tissues, laminate structures, or anycombination thereof.

The term “cycle” refers an interval of time characterized by theoccurrence of a sequence of events. In this instance, the cycle for anassembly begins when its web receives a material on its leading edge.Subsequently, the web via its assembly moves in such a manner so thatthe web can receive the material again. The end of the cycle for theassembly occurs at a time immediately prior to the material contactingthe web on its leading edge.

As used herein the term “machine direction,” designated MD, is thedirection parallel to the flow of the web through the equipment.

As used herein the term “cross machine direction,” designated CD, is thedirection that is substantially perpendicular to the machine direction.

As used herein the term “transverse width” is the width of the web inthe CD direction.

As used herein, the x-axis is parallel to the longitudinal centerline ofthe web(s) of the first and second upstream and downstream zones.

As used herein, the y-axis is perpendicular to the x-axis and thelongitudinal centerline of the web(s) of the first and second upstreamand downstream zones.

As used herein, the z-axis is perpendicular to the x-axis, the y-axis,and the top surface of the web.

Description:

FIG. 1 shows an example of an apparatus 10 that can carry out thepresent invention. A first web 12 is provided in a first upstream zone92 moving in the positive x direction 93 at a first web velocity. Afirst assembly 28 is provided to divert the first web 12 from the firstupstream zone 92 to a first intermediate zone 90. The first web 12 isdiverted by a first turnbar 14 such that the first web extends in thepositive 1 toward a second assembly 30. The first web 12 is turned, suchthat the longitudinal centerline 302 of the first web 12 in the firstintermediate zone 90 is perpendicular to the longitudinal centerline 300of the first web 12 in the first upstream zone 92.

The first web 12 is fed to a first idler 18 such that the first web 12in the first intermediate zone 90 is inverted. The first web 12 isinverted such that the first web 12 extends in the negative y directionaway from the second assembly 30. The first web 12 is then fed to asecond turnbar 16 where the first web 12 is diverted from the firstintermediate zone 90 to a first downstream zone 94. The first web 12 isturned such that the longitudinal centerline 304 of the first web 12 inthe first downstream zone 94 is parallel to the x-axis and moves in thepositive x direction 95.

Similarly, a second web 20 is provided in a second upstream zone 98moving in the positive x direction 99 at a second web velocity. Thesecond assembly 30 is provided to divert the second web 20 from thesecond upstream zone 98 to a second intermediate zone 96. The second web20 is diverted by a third turnbar 22 such that the second web extends inthe negative y direction toward the first assembly 28. The second web 20is turned, such that the longitudinal centerline 308 of the second web20 in the second intermediate zone 96 is perpendicular to thelongitudinal centerline 306 of the second web 20 in the second upstreamzone 98.

The second web 20 is fed to a second idler 26 such that the second web20 in the second intermediate zone 96 is inverted. The second web 20 isinverted such that the second web 20 extends in the positive y directionaway from the first assembly 28. The second web 20 is then fed to afourth turnbar 24 where the second web 20 is diverted from the secondintermediate zone 96 to a second downstream zone 100. The second web 20is turned such that the longitudinal centerline 310 of the second web 20in the second downstream zone 100 is parallel to the x-axis and moves inthe positive x direction 101.

As shown in FIGS. 2—5, a material applicator 32 is provided for placinga material 34 onto a first web 12 and a second web 20. The material 34can be a polymer as exampled by an adhesive or an elastomeric material.The material 34 can also be a thermoplastic or any non-woven fiber.Also, the material 34 may comprise a web from which discrete parts areformed, as discussed with regard to FIG. 15. Moreover, the materialapplicator 32 may apply the material 34 via an extrusion process, aspraying process or a joining process or any combination thereof.

In FIG. 2, a distal end 38 of the material 34 is shown in contact withthe leading edge 82 of the first web 12 which marks the beginning of thefirst assembly's cycle. The first web 12 in the first intermediate zone90 continues to receive the material 34 as the first assembly translatesin the positive x direction along a first plane 21. Because the firstassembly 28 translates in the positive x direction, the first web 12 inthe first intermediate zone 90 has a velocity, with respect to the firstassembly 28, which is lower than the first web velocity. In contrast,the second assembly 30 translates in the negative x direction along asecond plane 31 such that the second web 20 in the second intermediatezone 96 has a velocity, with respect to the second assembly 30, which isgreater than the second web velocity.

As shown in FIG. 3, the distal end 38 of the material 34 is in contactwith the trailing edge 84 of the first web 12. After the material 34 hasbeen applied across the transverse width of the first web 12 in thefirst intermediate zone 90, the first assembly 28 moves along the z-axisin the negative z direction 23. The second assembly 28 moves along thez-axis in the positive z direction 33 such that the second web 20 in thesecond intermediate zone 96 can receive the material 34 across itstransverse width.

As shown in FIG. 4, the distal end 38 of the material 34 is in contactwith the leading edge 86 of the second web 20 in the second intermediatezone 96 which marks the beginning of the second assembly's cycle. Thesecond web 20 in the second intermediate zone 96 continues to receivethe material 34 as the second assembly 30 translates in the positive xdirection along the first plane 21. Because the second assembly 30translates in the positive x direction, the second web 20 in the secondintermediate zone 96 has a velocity, with respect to the second assembly30, which is lower than the second web velocity. Contemporaneously, thefirst assembly 28 translates in the negative x direction along thesecond plane 31 such that the first web 12 in the first intermediatezone 90 has a velocity, with respect to the first assembly 28, which isgreater than the first web velocity.

As shown in FIG. 5, the distal end 38 of the material 34 is in contactwith the trailing edge 88 of the second web 20. After the material 34has been applied across the transverse width of the second web 20 in thesecond intermediate zone 96, the second assembly 30 moves in thenegative z direction 37. The first assembly 28 moves along the z-axis inthe positive z direction 27 such that the first web 12 in the firstintermediate zone 90 can receive the material 34 across its transversewidth.

The end of the cycle for the first assembly 28 corresponds to the momentimmediately before the distal end 38 of the material 34 contacts theleading edge 82 of the first web 12. Similarly, the end of the cycle forthe second assembly 30 is the moment immediately before the distal end38 of the material 34 contacts the leading edge 86 of the second web 20.

Although not shown in FIG. 3, when the distal end 38 of the material 34contacts the trailing edge 84 of the first web 12, the second assembly30 is positioned immediately behind the first assembly 28 such that therisk of losing material between the first assembly 28 and the secondassembly 30 is minimized. Similarly, although not shown in FIG. 5, whenthe distal end 38 of the material 34 contact the trailing edge 88 of thesecond web 20, the first assembly 28 is positioned immediately behindthe second assembly 30.

In the preceding figures, i.e. 2-5, the movement of both the firstassembly 28 and the second assembly 30 were shown as orthogonal toeither the x-axis or z-axis merely as examples of the movements of theassemblies. However, the assemblies are not constrained to move solelyin directions which are orthogonal to an axis described herein.Moreover, the movements of the assemblies are not constrained to movesolely in a linear fashion. For instance, the assembly movement maycomprise a curvilinear path.

A separating step may be included in the present invention (see FIG. 6).A separator 62 may be employed such that the material 34 is separatedfrom the trailing edge 84 of the first web 12. When the distal end 38 ofthe material 34 contacts the trailing edge 84 of the first web 12, theseparator 62 moves along a path 61. The separator 62 severs the distalend 38 of the material 34 from the trailing edge 84 of the first web 12.The separator 62 then moves along a path 63 such that the separator 62does not disturb the movement of the first assembly 28 or secondassembly 30. The separator 62 operates in a similar manner when severingthe distal end 38 of the material 34 from the trailing edge 88 of thesecond web 20 (See FIG. 7).

Because there are so many possibilities with regard to either thematerial 34 or the process utilized by the material applicator 32 toapply the material 34, the step of separation may be accomplished inmany different ways. The separator 62 can be a knife-edge which seversthe distal end 38 of the material 34 from the trailing edge 84 of thefirst web 12 or the trailing edge 88 of the second web 20. Moreover, ifthe material 34 comprises discrete parts, the separator may comprise aknife roll and an anvil roll (see discussion of FIG. 15). The separator62 may also comprise a hot air knife, a hot wire, a water jet, a laser,or any means of separation that is well known in the art.

Alternatively, the step of separation of the material 34 from thetrailing edge 84 of the first web 12 or the trailing edge 88 of thesecond web 20 can be accomplished by changing the velocity profile ofthe first assembly 28 or the velocity profile of the second assembly 30.For example, when the distal end 38 of the material 34 is in contactwith the trailing edge 84 of the first web 12, the first assembly 28accelerates to a higher velocity in the positive x direction than thevelocity of the first assembly 28 when the first web 12 is receiving thematerial 34. This acceleration to a higher velocity induces the material34 to break, thereby accomplishing the step of separation. Similarly,when the distal end 38 of the material 34 contacts the trailing edge 88of the second web 20, the separation of the material 34 from thetrailing edge 88 of the second web 20 can be accomplished byaccelerating the second assembly 30.

Alternatively, the step of separation may be accomplished via a timedprocess. For instance, if the material is an adhesive to be sprayed ontothe first web 12, the material applicator 32 ceases the process when thetrailing edge 84 of the first web 12 is no longer underneath thematerial applicator 32. In this instance, the material applicator 32ceases spraying the adhesive in between the trailing edge 84 of thefirst web 12 and the leading edge 86 of the second web 20, and thematerial applicator 32 begins spraying once the leading edge 86 of thesecond web 20 is underneath the material applicator 32. Similarly, thematerial applicator 32 ceases spraying between the trailing edge 88 ofthe second web 20 and the leading edge 82 of the first web 12.

FIGS. 8, 9, 10, and 11, are examples of the orientation of the material34 on either the first, second, or single web. In FIG. 8, the material34 is shown applied in a uniform manner to the web materialperpendicular to the y-axis. As an example of how to accomplish this,the first assembly translates in the positive x direction at the firstweb velocity such that the first web in the first intermediate zone isstationary with respect to the first assembly. Because the first web inthe first intermediate zone is stationary with respect to the firstassembly, the material is applied across the transverse width of thefirst web in the first intermediate zone such that the material isperpendicular to the longitudinal centerline of the first web.

FIG. 8A provides examples of the velocity profiles of the assemblies foraccomplishing the material orientation as shown in FIG. 8. As shown,time, denoted as “t”, t equal to zero, the first web in the firstintermediate zone begins to receive the material. While receiving thematerial, the velocity of the first assembly in the positive xdirection, denoted v1, is equal to the first web velocity. At time tequal to tl (tl representing the completion of 50% of the cycle for thefirst assembly), the transverse width of the first web has received thematerial. The first assembly subsequently completes the remainder of itscycle and gets back into a position such that the first web may receivethe material again. Because 50% of the first assembly's cycle is spentreceiving material across the transverse width of the first web, duringthe remaining 50% of the cycle, the amount of web which travels throughthe first intermediate zone is equal to the transverse width of thefirst web. Therefore, the material applicator provides the material tothe first web in the first intermediate zone on a portion of the firstweb having a length which is two times the transverse width of the firstweb.

The velocity profile of the second assembly is similar to that of thefirst assembly; however, the second web in the second intermediate zonebegins to receive the material at t equal to t2. Similarly, at t equalto t3 (t3 representing the completion of 50% of the cycle for the secondassembly) the transverse width of the second web has received thematerial.

In FIG. 9, the material 34 is shown applied to the web in the firstintermediate zone of the first assembly in two separate materialapplications 175 and 177. During the first application 175 of thematerial 34 to the first web, the velocity of the first assembly whiletranslating in the positive x direction is equal to the first webvelocity. The translation of the first assembly in the positive xdirection at the first web velocity causes the first web in the firstintermediate zone to be stationary with respect to the first assembly.The first web in the first intermediate zone receives the material 34across its transverse width for 50% of the first assembly's cycle. Theremaining 50% of the cycle, the first assembly alternates positions withthe second assembly and moves such that the first web can receive thematerial 34 during the second application 177. Similar to the firstapplication 175, during the second application 177 of material 34, thefirst assembly translates in the positive x direction at a velocitywhich equals the first web speed.

In this instance, however, the gap between the first application 175 andthe second application 177 occurs because during the first application175 the material applicator does not provide material 34 to a portion ofthe first web having a length which is two times the transverse width ofthe first web. Instead, the material applicator applies the material 34to a length of the first web which is less than two times the transversewidth of the first web. Thus, before the second application 177 ofmaterial 34 begins, a portion of the first web passes through the firstintermediate zone without receiving the material 34.

FIG. 10, shows the orientation of the material 34 on the web when thevelocity of the first assembly in the positive x direction is less thanthe first web velocity. If this is in fact the case, then the first webin the first intermediate zone has a positive velocity with respect tothe first assembly. Because the first web in the first intermediate zonehas a positive velocity with respect to the first assembly, the firstweb translates in the positive y direction thereby yielding a patternsimilar to that shown in FIG. 10.

FIG. 11, shows the orientation of the material 34 on the web when thevelocity of the first assembly in the positive x direction is greaterthan the first web velocity. If this is in fact the case, then the firstweb in the first intermediate zone, with respect to the first assembly,has a negative velocity with respect to the assembly. This causes thefirst web in the first intermediate zone to travel in the negative ydirection with respect to the first assembly.

Note that in both FIGS. 10 and 11, reference was made only to the firstweb. The same holds true for the second web; however, a positive secondweb velocity with respect to the second assembly, i.e. the secondassembly is translating at a higher velocity than the velocity of thesecond web, causes the second web in the second intermediate zone totranslate in the positive y direction. Therefore, a pattern similar tothat shown in FIG. 10 would occur. In contrast, a negative second webvelocity with respect to the second assembly (the second assemblytranslates at a lower velocity than the velocity of the second web)causes the second web in the second intermediate zone to translate inthe negative y direction with respect to the assembly. Therefore, apattern similar to that shown in FIG. 11 occurs.

Once the material 34 has been applied to the first web 12 or the secondweb, then a laminate structure 64 may be formed by joining the first web12 or second web with a third web 70 or fourth web, respectively. FIG.12 shows an example of how the laminate structure can be formed. Thefirst web 12 in the first downstream zone 94 proceeds into a nip roll atwhich point the first web 12 is combined with the third web 70. Thecombination or nipping takes place between roll A 66 and roll B 68. Thecombination of the first web 12 and the third web 70 produces a laminatestructure 64 on the downstream side of the nipping step. Similarly,although not shown in this figure, the second web could be combined witha fourth web in a similar manner. The discussion pertaining to theaddition of the joining step for a single web application occurs in thesection pertaining to FIG. 14.

The orientation of the web face prior to the joining step may be ofconcern. For example, if the material were an elastic, over which athird web 70 or fourth web were to be placed, then the web going over aturnbar needs to be positioned such that the elastic were facing upwardon the downstream side of the turnbar.

The first web 12 and second web 20 may be drawn from a single parentroll of material 40 which forms a parent web 48 and is cut via a slitter42 as shown in FIG. 13. The slitter 42 may comprise any suitable deviceknown in the art. For example, the slitter 42 can be a stationary bladeor may comprise an anvil roll and a cutting roll. The anvil roll andcutting roll may be configured such that they create a scissor cut orcreate a crush cut in a parent web 48.

For this embodiment, the parent roll 40 unwinds and creates a parent web48. The parent web 48 moves in the positive x direction towards theslitter 42. The slitter 42 cuts the parent web 48 and creates a firstweb 12 and a second web 20 from the parent web 48. The first web 12 andthe second web 20 are then turned in a direction parallel to the y-axis,i.e. the first web 12 extends in the negative y direction while thesecond web 20 extends in the positive y direction. Then, the first web12 and the second web 20 are turned such that the first web 12 and thesecond web 20 travel along a path parallel to the x-axis by the fifthturnbar 44 and the sixth turnbar 46, respectively. After going throughthe fifth turnbar 44, the first web 12 is provided to the first upstreamzone 92. Similarly, after going through the sixth turnbar 46, the secondweb 20 is provided to the second upstream zone 98.

Alternatively, the present invention may be performed on a single web152 using the apparatus 110 an example of which is shown in FIG. 14. Thesingle web 152 is fed from the unwind station 158 into the firstupstream zone 192 at a first upstream zone velocity in the positive xdirection 193. The single web 152 is diverted from the first upstreamzone 192 into the first intermediate zone 190 and into the firstassembly 128 by the first turnbar 114. The single web 152 is turned suchthat the single web 152 in the first intermediate zone 190 extends inthe positive y direction parallel to the y-axis. The single web 152 isthen inverted by the first idler 118 such that the single web 152extends in the negative y direction. Then the single web 152 is divertedfrom the first intermediate zone 190 to the first downstream zone 194 bythe second turnbar 116. The single web 152 is turned such that thesingle web 152 in the first downstream zone 194 moves in the positive xdirection 195.

The single web 152 is transported to the second upstream zone 198 viathe seventh turnbar 154, eighth turnbar 156, and third idler 160. Thesingle web 152, from the first downstream zone 194 is diverted by theseventh turnbar 154 such that the single web 152 moves in the positive ydirection 197. The single web 152 is fed to the eighth turnbar 156thereby turning the single web 152 such that the single web 152 moves inthe negative x direction 199. The single web 152 is then inverted by thethird idler 160 such that the single web 152 moves in the positive xdirection 201 and into the second upstream zone 198 at a second upstreamzone velocity.

The single web 152 is diverted from the second upstream zone 198 intothe second intermediate zone 196 and into the second assembly 130 by thethird turnbar 124. The single web 152 is turned such that the single web152 in the second intermediate zone 196 extends in the negative ydirection parallel to the y-axis. The single web 152 is then inverted bythe second idler 126 such that the single web 152 extends in thepositive y direction. Then the single web 152 is diverted from thesecond intermediate zone 196 to the second downstream zone 200 by thefourth turnbar 122. The single web 152 is turned such that the singleweb 152 in the second downstream zone 200 moves in the positive xdirection 203.

The first assembly 128 and the second assembly 130 are periodicallyoverlapped in an alternating fashion. Similar to the previousdiscussion, this allows a material to be continuously applied to thesingle web 152 in the first intermediate zone 190 and the secondintermediate zone 196, respectively.

Also, the single web 152 can be combined with a third web or fourth webin a similar manner as described above with regard to FIG. 12. Thecombining in this instance could take place in the first downstream zone194 or the second downstream zone 200 of the single web 152. Moreover,the step of separation may be accomplished in any manner describedherein.

FIG. 15 shows an example of how discrete parts may be appliedtransversely to a moving web using apparatus 210. The separation occursusing an anvil roll 204 and a knife roll 202. The knife roll 202 hasprotrusions which engage the anvil roll 204 to create the discrete parts206. Material 234 comprises a web and is partially looped around theanvil roll 204. As the protrustions of the knife roll 202 engage theanvil roll 204, discrete parts 206 are formed from the material 234. Theanvil roll 204 engages the second web 220 in the second intermediatezone 296 in order to join the discrete part 206 to the second web 220 inthe second intermediate zone 296. Thus, the discrete parts 206 arecombined with the second web 220 in the second intermediate zone 296 asthe second web 220 passes underneath the anvil roll 204.

After the second web 220 in the second intermediate zone 296 hasreceived the discrete part, the second assembly 230 translates in thepositive x direction such that the first assembly 228 can move into aposition such that the first web 212 in the first intermediate zone 290can receive the discrete part from the anvil roll 204. The anvil roll204 has a tangential velocity which is equal to the velocity of thefirst assembly 228 when in contact with the first assembly 228.Similarly, the anvil roll 204 has a tangential velocity which is equalto the velocity of the second assembly 230 when in contact with thesecond assembly 230.

The motions of the first assembly 28 and the second assembly 30discussed previously concerning FIGS. 2-5 are equally applicable in thisinstance regarding the first assembly 228 and the second assembly 230.Thus, the placement of discrete parts 206 on the first web 212 in thefirst intermediate zone 290 or the second web 220 in the secondintermediate zone 296 may be implemented with any of the embodimentsdiscussed herein.

Note that the turnbars mentioned herein, turn the first web second webor the single web in perpendicular directions. However, a turnbar mayturn a web at any given angle provided that the first assembly and thesecond assembly are given enough distance between each other.Specifically, there must be enough distance between the longitudinalcenterlines of each web allowing the first assembly and the secondassembly to have sufficient space to turn their respective webs in thepositive y direction and the negative y direction. Sufficient distancebetween the assemblies is required such that the first and secondassemblies can periodically overlap one another thereby allowing theirrespective webs to receive the material 34 across their transversewidth.

The devices described herein for diverting, turning, redirecting, orinverting a web have included turnbars and idlers. Despite thisdescription, any suitable methods of diverting, turning or redirecting aweb known in the art can be used in conjunction with the presentinvention. Also, any suitable methods of inverting a web known in theart may be used in conjunction with the present invention.

All embodiments mentioned within the specification are not constrainedto the application of a material across the entire transverse width ofthe first web, second web, or single web. The material application maybe across only a portion of the transverse width of the first web,second web, or single web. Also, the material application is notconstrained to beginning at the leading edge of the first web, secondweb, or single web and is also not constrained to ending at the trailingedge of the first web, second web, or single web.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method of placing a material on a single web having a transversewidth, the method comprising the steps of: providing the single web in afirst upstream zone such that the web is moving at a first upstream zonevelocity in the positive x direction; providing a first assembly fordiverting the single web from the first upstream zone to a firstintermediate zone and for diverting the single web from the firstintermediate zone to a first downstream zone; transporting the singleweb from the first downstream zone into a second upstream zone such thatthe single web is moving at a second upstream zone velocity in thepositive x direction; providing a second assembly for diverting thesingle web from the second upstream zone to a second intermediate zoneand for diverting the single web from the second intermediate zone to asecond downstream zone; periodically overlapping the first assembly andsecond assembly in an alternating fashion by translating the firstassembly and second assembly in a positive x direction in a first planeand a negative x direction in a second plane such that when the firstassembly translates in the positive x direction, the single web in thefirst intermediate zone has a velocity, with respect to the firstassembly, which is less than the first upstream zone velocity and suchthat when the second assembly translates in the positive x direction,the single web in the second intermediate zone has a velocity, withrespect to the second assembly, which is less than the second upstreamzone velocity; and alternately applying the material across at least aportion of the transverse width of the single web in the firstintermediate zone and across at least a portion of the transverse widthof the single web in the second intermediate zone such that theapplication of the material to the single web in the first intermediatezone and the single web in the second intermediate zone is continuous.2. The method of claim 1 further comprising the step of combining thesingle web with a third or fourth web to create a laminate structure. 3.The method of claim 1 further comprising the step of separating thematerial between the first assembly and the second assembly.
 4. Themethod of claim 1, wherein the material comprises a continuouslyextruded polymer.
 5. The method of claim 1, wherein the materialcomprises a continuously sprayed polymer.
 6. The method of claim 1,wherein translating the first assembly in the positive x directioncauses the single web in the first intermediate zone to be stationarywith respect to the first assembly and wherein translating the secondassembly in the positive x direction causes the single web in the secondintermediate zone to be stationary with respect to the second assembly.